molex MX150 User guide

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 1of 62
DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:
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100
Brian Zelinski Steve Verzyl Scott Marceau
TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
MX150 System
Sealed Product Line

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 2of 62
DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:
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Brian Zelinski Steve Verzyl Scott Marceau
TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Table of Contents
•Section 1: Product Introduction
•Section 2: Product Summary
•Section 3: Connector Assembly
•Section 4: Connector Mating
•Section 5: Service Instructions
•Section 6: Electrical Continuity Checking
•Section 7: Crimping
•Section 8: Hybrid Connector
•Section 9: Troubleshooting Guide
•Section 10: Packaging

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 3of 62
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Brian Zelinski Steve Verzyl Scott Marceau
TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
This instructions manual contains supplemental information pertaining to
the Molex 1.50 mm sealed Product Line. Additional information, keyway
and knockout patterns can be found on the sales drawings.
Single Row Assembly Sales Drawing
Receptacle
SD-33471-031.drw
SD-33471-041.drw
SD-33471-051.drw
SD-33471-061.drw
Blade
SD-33481-031.drw
SD-33481-041.drw
SD-33481-051.drw
SD-33481-061.drw
Dual Row Assembly
Receptacle
SD-33472-041.drw
SD-33472-061.drw
SD-33472-081.drw
SD-33472-121.drw
SD-33472-131.drw
SD-33472-161.drw
SD-33472-201.drw
Blade
SD-33482-041.drw
SD-33482-061.drw
SD-33482-081.drw
SD-33482-121.drw
SD-33482-161.drw
SD-33482-201.drw
Section 1: Product Introduction
MX150 System

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 4of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 1: Product Introduction MX150 System
Features and Benefits:
•Pre-assembled connector housings, seals and TPA components
•Simple crimp, poke and plug application
•Integral Terminal Position Assurance (TPA)
•Integral two way, mat and interface seals designed and tested to IP
67 and SAE USCAR-2, Rev 3 standards
•Easy terminal extraction and insertion
•Compatible with a wide range of UL (22 to 14 AWG) and SAE
Automotive (22 to 14) style wires
•Integral locking latch with secondary connector position assurance
(CPA) option
•Applied cost savings
•No need to crimp individual wire seals
•Locks terminals into housings and prevents terminals from backing
out
•More than just waterproof, a true sealed connector system tested
under submersed conditions
•Quick, low cost field repairs
•Supports a wide range of power and signal applications
•Assures positive mating of connector and prevents accidental
disengagement during high vibration and severe shock application

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 5of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 1: Product Introduction MX150 System
MX150 Applications:
•Passenger Automobiles (Exclusively for MX150 family)
•Off Highway Construction Equipment
•Agriculture Equipment
•Trucks, Busses and RVs
•Commercial and Recreational Marine Equipment
•Material Handling Equipment
•Lawn and Garden Equipment
•Outdoor Lighting
•Industrial Control
For product ordering information, please contact your Molex Inside
Sales Representative at [phone]. This User Manual can be
found at www.molex.com/ind/mx150.html

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 6of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Grommet Seal
Housing
TPA
Grommet Cap
6 Way 2X3
Blade Connector
Section 2: Product Summary
A. Connector Assemblies

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 7of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Housing
Grommet Seal
Grommet Cap
Perimeter Seal
TPA
CPA
(Optional)
16 Way 2X8 Standard
Receptacle Connector
Section 2: Product Summary
B. Connector Assemblies (continued)

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 8of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
CPA
(Optional)
Grommet Cap
Grommet Seal
Housing
Perimeter Seal
TPA
16 Way Hybrid
Receptacle Connector
Section 2: Product Summary
C. Connector Assemblies (continued)

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 9of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 2: Product Summary
D. Receptacle/Blade Terminal
Terminal Features
Base Material - Copper Alloy
Plating Options - Tin, Gold, Silver
Wire Sizes: 14,16,18,20,22 AWG
1.5, 1.0, 0.8, 0.5 mm2
Refer to Section 7 for crimping details.
Blade Terminal
Receptacle Terminal
Orientation Feature
Orientation Feature

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 10 of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 2: Product Summary
E. Product Identification
- All parts are laser etched with:
1. Molex Part Number
2. Date Code (YYDDD)
- YY = Last Digit of Year
- DDD = Day of Year
Note – MX150 16 way hybrid and MX150 20 way DO NOT have Laser
marking.
DDD = Day of YearYY = Last Digit of Year
Molex Part Number

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 11 of 62
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TPA’s shown in pre-lock
TPA’s shown in “As Shipped” condition.
The TPA should remain in the pre-lock position until all circuits are
loaded. TPA movement distance from pre-lock to final lock = 5.0 mm
in both Blade and Receptacle connectors.
The TPA should never be removed from the connector!
Section 3: Connector Assembly
A. “As Shipped” connector positions

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 12 of 62
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TPA shown in “Pre
-
lock” position.(Fig.10
-
a)
TPA shown in “lock” position. (Fig 10-b)
The TPA should never be removed from the connector!
Cross section of TPA in pre/ lock
Pre-lock
Lock
Section 3: Connector
Assembly
B. TPA in Pre-lock and Lock
5.0 mm
Fig. 10
-
a
Fig. 10
-
b

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 13 of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
With TPA still in pre-lock position, orient terminal to rear of connector.
Grip the wire no less than 30 mm from the terminal insulation crimp
align the orientation feature and insert through appropriate circuit
opening. If resistance is encountered, retract the terminal and adjust
the angle of insertion. Continue inserting the terminal until it stops and
locks up on the lock finger with an audible click.
Correct Orientation
90
°
°°
°
Mis-orientation
Section 3: Connector Assembly
C. Terminal Installation

APPLICATION SPECIFICATION
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EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 14 of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
With TPA still in pre-lock position,
orient terminal to rear of
connector. Align the orientation
feature and insert through
appropriate circuit opening. If
resistance is encountered, retract
the terminal and adjust the angle
of insertion. Continue inserting the
terminal until it stops and locks up
on the lock finger with an audible
click. Once the audible click is
heard, stop inserting the terminal.
Follow Push, Click, Pull method
of terminal installation.
PUSH
PULL
NO!!!
WRONG!!
CLICK

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 15 of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 3: Connector Assembly
D. Seal Plug Installation
With TPA still in pre-lock position, orient seal plug to rear of connector.
Align the orientation feature and insert through appropriate circuit
opening. If resistance is encountered, retract the terminal and adjust
the angle of insertion. Continue inserting the terminal until it stops and
locks up on the lock finger with an audible click. Seal plugs can be used
on both Blade, and Receptacle connectors.
Orientation feature is highlighted
blue for reference only
Seal plug can not be used in shorting
bar circuits!
Orientation Feature

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 16 of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 3: Connector Assembly
D. Seal Plug Installation continued
YES!
CORRECT!
NO!
WRONG!
Backwards
!
180
°
out of alignment!
90
°
out of alignment!

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 17 of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 3: Connector Assembly
D. Seal Plug Installation continued
Cavity plugs can be trimmed flush to
avoid wire chafing, the decision to trim is
the discretion of the harness supplier.
Cavity plugs must be installed, and
trimmed before wires are installed. Cavity
plugs can be used on both Blade, and
Receptacle connectors.
Never trim cavity plugs with
wires installed!

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 18 of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 3: Connector Assembly
D. Seal Plug Installation continued
Cavity plugs can be trimmed flush to
avoid wire chafing, the decision to trim is
the discretion of the harness supplier.
Cavity plugs must be installed, and
trimmed before wires are installed. Cavity
plugs can be used on both Blade, and
Receptacle connectors.
Never trim cavity plugs with
wires installed!

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 19 of 62
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
With the Receptacle terminals fully installed, the TPA
can be seated into its final lock position by applying
an even force to both ends until it comes to a stop,
with an audible click. TPA movement distance from
pre-lock to final lock is 5.0 mm.
The TPA should never be fully removed!
Section 3: Connector Assembly
E. Seating the TPA Receptacle side

APPLICATION SPECIFICATION
REVISION: ECR/ECN INFORMATION: SHEET No.
EC No: ABC2001-9999
1 DATE: 2008/16/03
TITLE:
MX150 Application Guide 20 of 62
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A modified process can be used for the Blade terminal. Using a pair on
needle nose pliers, apply even pressure to the TPA. If the TPA resists
it may be detecting a partially installed terminal. Pull the TPA back into
its pre-lock position and make sure all terminals are fully installed.
Upon completion, the TPA can be seated. TPA movement distance
from pre-lock to final lock is 5.0mm.
The TPA should never be fully removed!
Section 3: Connector Assembly
F. Seating the TPA Blade side